Hoshizaki KM-1100MAJ50 User manual

Brand: Hoshizaki

Model: KM-1100MAJ50

Type: User manual

Models

KM-1100MAJ50

Modular Crescent Cuber

Service Manual

Number: 73231

Issued: 9-12-2018

hoshizakiamerica.com

WARNING

Only qualied service technicians should install and service the appliance. To

obtain the name and phone number of your local Hoshizaki Certied Service

Representative, visit www.hoshizaki.com. No service should be undertaken until

the technician has thoroughly read this Service Manual. Failure to service and

maintain the appliance in accordance with this manual will adversely affect safety,

performance, component life, and warranty coverage. Proper installation is the

responsibility of the installer. Product failure or property damage due to improper

installation is not covered under warranty.

Hoshizaki provides this manual primarily to assist qualied service technicians in the

service of the appliance.

Should the reader have any questions or concerns which have not been satisfactorily

addressed, please call, send an e-mail message, or write to the Hoshizaki Technical

Support Department for assistance.

Phone: 1-800-233-1940; (770) 487-2331

Fax: 1-800-843-1056; (770) 487-3360

E-mail: techsuppor[email protected]

618 Highway 74 South

Peachtree City, GA 30269

Attn: Hoshizaki Technical Support Department

Web Site: www.hoshizaki.com

NOTE: To expedite assistance, all correspondence/communication MUST include the

following information:

• Model Number

• Serial Number

• Complete and detailed explanation of the problem.

CONTENTS

Important Safety Information ................................................................................................. 4

I. Construction and Water/Refrigeration Circuit Diagram ....................................................... 6

A. Construction .................................................................................................................. 6

B. Water/Refrigeration Circuit Diagram .............................................................................. 7

II. Sequence of Operation and Service Diagnosis ................................................................. 8

A. Sequence of Operation Flow Chart ............................................................................... 8

B. Service Diagnosis ....................................................................................................... 10

C. Control Board Check ................................................................................................... 17

D. Bin Control Check ....................................................................................................... 18

E. Float Switch Check and Cleaning ............................................................................... 19

F. Thermistor Check ......................................................................................................... 21

G. Control Switch ............................................................................................................. 21

H. Diagnostic Tables ........................................................................................................ 22

I. Freeze-Up Check List ................................................................................................... 26

III. Controls and Adjustments ............................................................................................... 27

A. Control Board Layout .................................................................................................. 28

B. LED Lights and Audible Alarm Safeties ....................................................................... 29

C. Settings and Adjustments ............................................................................................ 30

1. Default Dip Switch Settings .................................................................................... 30

2. Harvest Timer (S4 dip switch 1 & 2) ...................................................................... 31

3. Pump-Out Timer/Harvest Time During Pump-Out (S4 dip switch 3 & 4) ............... 31

4. Pump-Out Frequency Control (S4 dip switch 5) ..................................................... 32

5. Harvest Pump Time (Harvest Assist Duration) (S4 dip switch 6) ........................... 32

6. Harvest Pump Time (Harvest Assist) (S4 dip switch 7) ........................................ 33

7. Factory Use (S4 dip switch 8)................................................................................. 33

8. Freeze Timer (S4 dip switch 9 & 10) ...................................................................... 34

9. Float Switch Selector (S5 dip switch 1) ................................................................. 34

10. Rell Counter (S5 dip switch 2 and 3) .................................................................. 34

11. Minimum Harvest Time (S5 dip switch 4) ............................................................. 35

12. Anti-Slush (S5 dip switch 5) ................................................................................. 35

IV. Refrigeration Circuit and Component Service Information.............................................. 36

A. Refrigeration Circuit Service Information .................................................................... 36

B. Component Service Information .................................................................................. 39

V. Maintenance .................................................................................................................... 40

VI. Preparing the Appliance for Periods of Non-Use ............................................................ 41

VII. Disposal ......................................................................................................................... 43

VIII. Technical Information .................................................................................................... 44

A. Specication and Performance Data Sheets ............................................................... 44

B. Wiring Diagram ........................................................................................................... 45

IMPORTANT

This manual should be read carefully before the appliance is serviced. Read

the warnings and guidelines contained in this manual carefully as they provide

essential information for the continued safe use, service, and maintenance of the

appliance. Retain this manual for any further reference that may be necessary.

Important Safety Information

Throughout this manual, notices appear to bring your attention to situations which could

result in death, serious injury, damage to the appliance, or damage to property.

WARNING Indicates a hazardous situation which could result in death or

serious injury.

NOTICE Indicates a situation which could result in damage to the

appliance or property.

IMPORTANT Indicates important information about the use and care of the

appliance.

WARNING

The appliance should be destined only to the use for which it has been expressly

conceived. Any other use should be considered improper and therefore dangerous.

The manufacturer cannot be held responsible for injury or damage resulting from

improper, incorrect, and unreasonable use. Failure to service and maintain the

appliance in accordance with this manual will adversely affect safety, performance,

component life, and warranty coverage and may result in costly water damage.

To reduce the risk of death, electric shock, serious injury, or re, follow basic

precautions including the following:

• Only qualied service technicians should install and service this appliance.

• The appliance must be installed in accordance with applicable national, state, and

local codes and regulations.

• Electrical connection must be hard-wired and must meet national, state, and local

electrical code requirements. Failure to meet these code requirements could result

in death, electric shock, serious injury, re, or severe damage to equipment.

• The icemaker requires an independent power supply of proper capacity. See the

nameplate for electrical specications. Failure to use an independent power supply

of proper capacity can result in a tripped breaker, blown fuses, damage to existing

wiring, or component failure. This could lead to heat generation or re.

• THE ICEMAKER MUST BE GROUNDED. Failure to properly ground the icemaker

could result in death or serious injury.

• Move the control switch to the "OFF" position and turn off the power supply before

servicing. Lockout/Tagout to prevent the power supply from being turned back on

inadvertently.

• To reduce the risk of electric shock, do not touch the control switch with damp

hands.

• Do not make any alterations to the unit. Alterations could result in electric shock,

injury, re, or damage to the unit.

• The appliance is not intended for use by persons (including children) with reduced

physical, sensory, or mental capabilities, or lack of experience and knowledge,

unless they have been given supervision or instruction concerning use of the

appliance by a person responsible for their safety.

WARNING, continued

• Children should be properly supervised around this appliance.

• Do not climb, stand, or hang on the appliance or allow children or animals to do so.

Serious injury could occur or the appliance could be damaged.

• Do not use combustible spray or place volatile or ammable substances near the

appliance. They might catch re.

• Keep the area around the appliance clean. Dirt, dust, or insects in the appliance

could cause harm to individuals or damage to the appliance.

NOTICE

• Follow the instructions in this manual carefully to reduce the risk of costly water

damage.

• In areas where water damage is a concern, install in a contained area with a oor

drain.

• Install the appliance in a location that stays above freezing. Normal operating

ambient temperature must be within 45°F to 100°F (7°C to 38°C).

• Do not leave the icemaker on during extended periods of non-use, extended

absences, or in sub-freezing temperatures. To properly prepare the icemaker for

these occasions, follow the instructions in "VI. Preparing the Appliance for Periods

of Non-Use."

• Do not place objects on top of the appliance.

• The dispenser unit/ice storage bin is for ice use only. Do not store anything else in

the dispenser unit/ice storage bin.

I. Construction and Water/Refrigeration Circuit Diagram

A. Construction

1. Air-Cooled Models (MAJ)

Water Supply Inlet

Condenser

Drier

Control Box

Spray Tubes

Control Switch

Water Pump

Float Switch

Compressor

Thermostatic

Expansion Valve

Fan Motor

Hot Gas Valve

Cleaning Valve

Inlet Water Valve

Liquid Line Valve

High-Pressure

Switch

B. Water/Refrigeration Circuit Diagram

1. Air-Cooled Models (MAJ)

Water Supply

Float Switch

Drain

Check Valve

Thermostatic Expansion Valve

Compressor

Hot Gas

Valve

High-Pressure

Switch

Strainer

Fan

Drier

Condenser

Evaporator

Discharge Line

Suction Line

Water Pump

Thermistor

Spray Tubes

Inlet Water Valve

Freeze

Pump Out

Water

Tank

Refrigeration Circuit

Water Circuit

Heat

Exchanger

Liquid Line Valve

Cleaning

Valve

II. Sequence of Operation and Service Diagnosis

A. Sequence of Operation Flow Chart

1. Operation Flow Chart

FS check

1 to 3-min. harvest timer in

control (S4 dip switch 1 & 2)

Legend:

BC–bin control

CB–control board

Comp–compressor

FM–fan motor

FS–oat switch

HGV–hot gas valve

HPT–harvest pump time

LLV –liquid line valve

PM–pump motor

WV–inlet water valve

Components Energized when the Control Switch is in the "WASH" Position

The "WASH" position on the control switch is used when cleaning and sanitizing the unit. When in the "WASH" position, power is supplied

to the pump motor. With the cleaning valve closed, the cleaner and sanitizer ow over the outside of the evaporator plate assembly. With the

cleaning valve open, the cleaner and sanitizer ow over both the outside and the inside of the evaporator plate assembly.

Note: Close the cleaning valve after cleaning and sanitizing are complete, otherwise the unit will not restart when the control

switch is placed in the "ICE" position.

Operation Flow Chart

1. 1-Minute

Fill Cycle

Cycle

Steps

2. Harvest Cycle

• WV time: 6 min. or the length of harvest minus HPT

setting (S4 dip switch 6), whichever is shorter.

• Max. harvest time: 20 min.

Thermistor

in control

3. Freeze Cycle

• Min. freeze time: 5 min.

• Max. freeze time: freeze timer setting (S4

dip switch 9 & 10).

FS in control

4. Pump-Out Cycle

• Factory set for every 10th

cycle

(S4 dip switch 5)

• Pump motor stops for

2 sec., then reverses for

10/20 sec.

(S4 dip switch 3 & 4)

WV energized

FS open

Comp energized

FM energized

HGV energized

WV energized

Thermistor temperature reaches

48°F (9°C) (3.9 kΩ or less). Harvest

timer starts.

FS open

Comp energized

FM energized

PM energized

LLV energized

HGV de-energized

FS closed

Comp energized

FM energized

HGV energized

PM de-energizes for 2 sec.,

then reverses for 10/20 sec.

LLV de-energized

FS check

Startup

If FS is open, Comp stops and cycle

returns to 1-Min. ll.

5-min.

minimum

freeze timer in

control

FS closed

FS opens or freeze

timer terminates

50 sec.

PM energized

WV de-energized

Harvest Pump

Time

Anti-Slush

Thermistor temperature

reaches 36°F (2.2°C)

(5.8 kΩ).

PM de-energized for

10 sec.

2. Shutdown Flow Chart

Shutdown Flow Chart

Legend:

BC–bin control

1. Bin Full

Within 10 sec.

after ice contacts

BC bulb,

icemaker shuts

down.

Shutdown

and Restart

Operation

Ice contacts BC bulb

2. Icemaker Off

All components

de-energized.

3. Ice Level Lowered

No ice touching BC bulb.

Icemaker starts at

"1. 1-Minute Fill Cycle."

BC closed

BC open

All components

de-energized

To 1. 1-Minute Fill Cycle

B. Service Diagnosis

WARNING

• The appliance should be diagnosed and repaired only by qualied service

personnel to reduce the risk of death, electric shock, serious injury, or re.

• Risk of electric shock. Control switch in "OFF" position does not de-energize all

loads Use extreme caution and exercise safe electrical practices.

• Moving parts (e.g., fan blade) can crush and cut. Keep hands clear.

• Before servicing the appliance, move the control switch to the "OFF" position and

turn off the power supply.

• CHOKING HAZARD: Ensure all components, fasteners, and thumbscrews are

securely in place after the appliance is serviced. Make sure that none have fallen

into the dispenser unit/ice storage bin.

• Make sure all food zones in the appliance and dispenser unit/ice storage bin are

clean after service.

The diagnostic procedure is a sequence check that allows you to diagnose the electrical

system and components. Before proceeding, check for correct installation, proper voltage

per nameplate, and adequate water supply. Check CB using the steps in "II.C. Control

Board Check." Check dip switch settings to assure that S4 dip switches and S5 dip

switches 1 through 5 are in the factory default position. S4 dip switch 1, 2, 3, 4, and 5 are

cleaning adjustments and the settings are exible. For factory default settings,

see "III.C.1. Default Dip Switch Settings."

Note: • On 208-230/60/1 models with main transformer and 208-230/60/3 models,

the appliance neutral (W) is provided through the main transformer. To conrm

a good neutral, check for 60VAC from white (W) neutral to ground (GND).

If60VAC is present, neutral is good. If 60VAC is not present, check 208-230VAC

main power supply to main transformer. If 208-230VAC is present, check main

transformer continuity.

• When checking voltage from the CB K1 connector (10 pin connector), pull

CBK1connector out slightly to allow room for multimeter test leads contact.

1) Turn off the power supply, then access the control box. Move the control switch to the

"OFF" position. Clear any ice from BC bulb.

2) Check that BC is closed and the 115VAC 10A fuse is good.

1. Sequence and Component Diagnosis

3) Power On: Turn on the power supply, then move the control switch to the "ICE" position.

A 5-sec. delay occurs. CB red "POWER OK" LED and CB green "BC CLOSED" LED

turn on. If CB yellow "BC OPEN" LED is on (indicating a full bin), check CB K4 red

jumper. Move ice away from BC bulb.

Note: • CB red "POWER OK" LED remains on unless the 10.5VAC power supply is

interrupted (K2 connector).

• Check CB using the steps in "II.C. Control Board Check."

• Conrm CB green "BC CLOSED" LED is on. If CB yellow "BC OPEN" LED is on,

conrm CB K4 jumper is in place. Otherwise, CB yellow "BC OPEN" LED is on

and appliance will not start.

a) Power On Diagnosis: If CB red "POWER OK" LED is off, conrm 10A fuse is good.

Check for 115VAC at control switch #1 (LBU) to neutral (W) then at control switch

#2(P) to neutral (W). If 115VAC is present on #1 (LBU) and not on #2(P), replace

control switch. If 115VAC is present on control switch #2 (P), check for 115VAC at

HPS (P) to neutral (W) then HPS (BK) to neutral (W). If115VAC is present at HPS

(P) and not at HPS (BK), HPS is open. See HPS Diagnosis below. If 115VAC is

present at HPS (BK), check for 10.5VAC at CB K2#1 red wire to CB K2 #2 red wire.

If 10.5VAC is not present, check that the cleaning valve is closed and the interlock

switch is closed. Next, check CT continuity. If open, replace CT.

b) HPS Diagnosis: Check that the condenser coil is not clogged or restricted. Let

refrigeration circuit pressures equalize. If HPS does not reset and pressures are

equalized, replace HPS. If pressures are not equalized, reclaim refrigerant and

diagnose refrigeration circuit restriction. Check that there are no restrictions in the

refrigeration circuit.

Harvest Cycle: HGV, strainer, or check valve.

Freeze Cycle: FM, TXV, LLV, strainer, check valve, drier, and damaged line set or

tting.

Conrm that the location meets installation requirements:

• The appliance is not intended for outdoor use. Normal operating ambient temperature

should be within 45°F to 100°F (7°C to 38°C).

• Allow 12" (30 cm) clearance at rear, sides, and top for proper air circulation and ease

of maintenance and/or service should they be required.

• The appliance should not be located in a corrosive environment.

4) 1-Min. Fill Cycle – LED 4 is on. WV and X11 relay energize. After 1 min., CB checks for

a closed FS. If FS is closed, the harvest cycle begins. If harvest cycle begins (Comp,

HGV, and FM energized), continue to step 5a. If FS is open, WV remains energized

until FS closes (low water safety protection during initial start up and at the end of each

harvest). Diagnosis: Check that water enters the water tank. If not, check that the water

supply line shut-off valve is open and screens or external lters are clear. Check for

115VAC at CB K1 #6 (O) to neutral (W). If 115VAC is not present, replace CB. If 115VAC

is present, and WV does not energize, check for 115VAC at WV. If 115VAC is present,

check coil continuity. Ifopen, replace WV. If the water tank lls, but the appliance fails to

start harvest (Comp energized), check for open FS. See "II.E. Float Switch Check and

Cleaning." If FS is closed and CB fails to start the harvest cycle after 1 min., replace

CB.

5a) Initial Harvest Cycle – LEDs 1, 4, and 2 are on. WV and X11 relay continue. Comp,

FM, HGV, and X10 relay energize. CBmonitors the warming of the evaporator via the

thermistor located on the suction line. When the thermistor reaches 48°F (9°C), CB

reads 3.9 kΩ from the thermistor and turns harvest termination over to the harvest

timer (S4 dip switch 1 & 2 and S5 dip switch 4). WV and X11 relay are energized during

harvest for a maximum of 6 min. or the length of harvest minus HPT setting (S4 dip

switch 6), whichever is shorter. See step 5b below.

a) Comp Diagnosis: Check that evaporator is warming. Ifnot, conrm that Comp

energizes. If not, check for 115VAC at CB K1 #1 or #9 (V) to neutral (W). If 115VAC is

not present, check for 115VAC at CB K1 #7 or #10 (LBU) to neutral (W). If115VAC is

present at #7 or #10 (LBU) and not at #1 or #9 (V), replace CB. If 115VAC is present,

check for 115VAC at CR or MC solenoid. If 115VAC is present, conrm contacts are

closed. If not, replace CR or MC. If CR or MC contacts are closed, check Comp

external overload, Comp start and run capacitors, Comp start relay, and Comp motor

winding.

b) HGV Diagnosis: If Comp is energized and evaporator is not warming, check that

HGV energizes and opens. Check for 115VAC at CB K1 #2 (P) to neutral (W).

If115VAC is not present, replace CB. If 115VAC is present, check for 115VAC at HGV

coil and check HGV coil continuity. Replace as needed.

c) LLV Diagnosis: Conrm that LLV is de-energized and closed (not bypassing).

Ifenergized, replace CB. If de-energized and bypassing, replace LLV.

5b) Harvest Pump Timer – LEDs 1, 3, and 2 are on. When the thermistor reaches 48°F

(9°C), CB reads 3.9 kΩ from the thermistor and turns harvest termination over to the

harvest timer (S4 dip switch 1 & 2 and S5 dip switch 4). When WV de-energizes,

LED 4 turns off, X11 relay de-energizes and LED 3 turns on. PM energizes. Comp, FM,

HGV, and X10 relay continue.

Diagnosis: Place a thermometer on the suction line next to the thermistor. Has it

warmed to 48°F (9°C) or warmer? Conrm thermistor status. See "II.F. Thermistor

Check." If the thermistor reading is in proper range, dip switch 7 is on, and PM does

not energize before harvest terminates, replace CB. If WV continues, check for 115VAC

at CB K1 #6 (O). If115VAC is present, and LED 4 is off, replace CB. If LED 3is on

and PM is not energized, check for 115VAC at CB K1 #5(DBU). If115VAC is not

present, replace CB. If 115VAC is present and PM is not energized, check for 115VAC

at X10relay terminal #7 (Y) to neutral (W). If 115VAC is not present, check for 115VAC

at X10 relay terminal #3 (P) to neutral (W) and X10 relay terminal #5 (Y) to neutral (W).

If 115VAC is present on terminal #3(P) and not on terminal #5 (Y), replace X10 relay.

If 115VAC is present on X10 relay terminal #7 (Y) and PM is not energized, check for

115VAC at X10 relay terminal #4 (R) to neutral (W) and terminal #6 (DBU) to neutral

(W). If 115VAC is present on terminal #6(DBU) and not on terminal #4 (R), replace

X10relay. If 115VAC is present on X10relay terminal #4 (R), check control switch

contact continuity between terminals #4(R) and #5(W/R). Ifcontacts are open, replace

control switch. If contacts are closed and 115VAC is present between control switch

terminal #5 (W/R) and neutral (W), check PM capacitor and motor winding continuity.

5c) Initial Harvest Cycle Termination Diagnosis: When the thermistor reaches 48°F

(9°C), CB reads 3.9 kΩ from the thermistor and turns harvest termination over to

the harvest timer (S4 dip switch 1 & 2 and S5 dip switch 4). Check discharge line

temperature. For a thermistor check, see "II.F.Thermistor Check." If 1-min. ll cycle

starts after harvest timer terminates, check that FS is clean and operating properly, see

"II.E. Float Switch Check and Cleaning." If FS is closed, CB proceeds to the next cycle.

Ifnot, replace CB.

Note: The minimum total time allowed by CB for a complete harvest cycle is based on

S5 dip switch 4. Maximum harvest time allowed is 20 min.

NOTICE! S4 dip switch 7 must remain on. Otherwise, PM will not energize during

the last seconds of harvest.

6) Freeze Cycle – LED 1 is on. Comp, FM, and PM continue. FM and LLV energize. HGV

and X10 relay de-energize. Appliance is held in freeze by a 5-min. short cycle protection

timer. After 5-min. short cycle protection timer terminates and FS opens, freeze cycle

terminates.

Note: PM power supply switches from CBK1 #5(DBU) in harvest to K1 #4 (R) in freeze.

Anti-Slush: When anti-slush is enabled (S5 dip switch 5 "ON"), PM de-energizes when

thermistor reaches 36°F (2.2°C) (5.8kΩ) for 10 sec. then, energizes for the remainder of

the freeze cycle.

a) Freeze Cycle Diagnosis: Conrm Comp, FM, and PM continue. Conrm that FM

and LLV energize. Conrm WRV opens. Next, conrm HGV and X10 relay de-

energize. During the rst 5 min. of freeze, conrm evaporator is cooling. If not,

conrm WV de-energized (not leaking by), HGV de-energized (not bypassing), LLV

and FM energize, TXV and HM operate correctly, WRV opens, Comp is efficient,

and refrigerant charge is correct. See "VIII.A. Specication and Performance Data

Sheets."

b) Comp and FM Diagnosis: If Comp and FM de-energize once freeze begins, check

that appliance has not shut off on HPS ("POWER OK" LED off). If so, check "3)b)

HPS Diagnosis" above. If CB "POWER OK" LED is on, check for 115VAC at CB K1

#1 (V) or #9 (V) to neutral (W). If 115VAC is not present and LED 1 is on, replace CB.

If 115VAC is present, check for 115VAC at CR or MC coil. If 115VAC is present, check

CR or MC coil and contact continuity. Replace as needed. If CR or MC is okay, check

Comp start relay and start and run capacitors. Next, check Comp motor winding

continuity. If Comp is energized but evaporator is not cooling, check for an inefficient

Comp. See "VIII.A. Specication and Performance Data Sheets."

FM Diagnosis: If Comp is energized but FM is not, check CB K1 #1 (V) and #9 (V)

wiring circuit for loose connection. If connections are good, check FM capacitor,

motor winding, and blade for binding.

c) WV and HGV Diagnosis: If WV is energized, check for 115VAC at CB K1 #6 (O) to

neutral (W). If 115VAC is present after PM energizes in harvest cycle, replace CB.

If 115VAC is not present, replace WV (bypassing). If HGV did not de-energize at

the end of harvest, check for 115VAC at CB K1 #2 (P) to neutral (W). If 115VAC is

present 50 sec. after PM energizes, replace CB. If 115VAC is not present, replace

HGV (bypassing).

d) PM Diagnosis: Conrm water is owing over evaporator from PM and not WV. If PM

de-energizes once freeze begins, check for 115VAC at CB K1 #4 (R) to neutral (W).

If 115VAC is not present, replace CB. If 115VAC is present and PM is de-energized,

check for 115VAC at control switch #5 (W/R) to neutral (W). If 115VAC is present at

CB K1 #4 (R) and not at control switch #5 (W/R), check control switch continuity

between #5 (W/R) and #4 (R). Replace as needed. If 115VAC is present at control

switch #5 (W/R) to neutral (W), check PM capacitor and motor winding continuity.

e) LLV Diagnosis: If LLV does not energize, check for 115VAC at CB K1#3 (BK) to

neutral (W). If 115VAC is not present, replace CB. If 115VAC is present, check coil

voltage and continuity.

f) Refrigerant Pressures and TXV Diagnosis: If evaporator is still not cooling, check

refrigerant pressures. See "VIII.A. Specication and Performance Data Sheets."

Next, check TXV for proper operation. Remove TXV bulb and hold it in your hand,

refrigerant low-side pressure should rise, place TXV bulb in ice water, refrigerant

low-side pressure should drop. A 10 to 15 pound pressure swing between warm and

cold conditions indicate a good TXV. If a 10 to 15 pound swing is not present, replace

TXV.

g) Freeze Termination Diagnosis: After 5 min. in freeze, disconnect CB K5 FS

connector. 15 sec. later appliance should switch out of the freeze cycle (15 second

delay after FS opens before terminating the freeze cycle). If appliance remains in

freeze longer than 15 sec. after FS removed, replace CB. If appliance switches with

FS removed but would previously not switch out of freeze with FS connected (long

freeze - 3 beep alarm), see "II.E. Float Switch Check and Cleaning."

Note: Normal freeze cycle will last 20 to 40 min. depending on model and conditions.

Cycle times and pressures should follow performance data provided in this

manual. See "VIII.A. Specication and Performance Data Sheets."

h) Short Freeze Cycle Diagnosis: Conrm water tank lls and overows during 1 min.

ll and harvest cycles. If not, check water supply lters, shut-off valve, WV screen.

Ifwater tank empties before 5 min. timer terminates and freeze cycle is short, check

that CV is not leaking by (water owing down the potable drain). If CV is leaking by,

remove and clean CV, replace rubber seat and spring if necessary. If water tank is

full, see "II.E. Float Switch Check and Cleaning." for erratic operating FS.

7) Pump-Out Cycle – LEDs 1, 3, and 2 are on (10/20 second pump-out). Timing of the

rst pump-out is determined by S4 dip switch 5. See the table below.

Control Board Settings

S4 Dip Switch Setting

Pump-Out Frequency Control Board

No. 5

OFF Every 10 cycles After 11th freeze cycle

ON Every cycle After 2nd freeze cycle

Comp and FM continue, HGV energize.

Note: If S4 dip switch 3 & 4 are set to 3 off and 4 on, LED 4 turns on and WV and X11

relay energize, energizing X10 relay. NOTICE!S4dip switch 3 & 4 must not be set

to 3 off and 4 on. Otherwise, PM will rotate in freeze cycle direction instead of

pump-out direction.

LLV de-energizes. PM stops for 2 sec., then reverses for 10/20 sec. depending on

pump-out timer (S4dip switch 3 & 4) setting. When the pump-out timer terminates,

pump-out is complete. The pump-out frequency control (S4 dip switch 5) is factory set,

and generally no adjustment is required. However, the pump-out frequency control can

be set to have a pump-out occur every 10 cycles or every cycle. For details, see "III.C.4.

Pump-Out Frequency Control (S4 dip switch 5)."

Pump-Out Diagnosis: In the freeze cycle before pump-out (see table above), after

5min. of freeze disconnect CB black K5 connector (FS connector). Check that PM

stops and re-starts. Next, check that PM rotation is correct (water owing down the

drain through CV). If PM does not stop and re-start, check that CB LEDs 1, 3, and 2

are on. If not, replace CB. IfLEDs1,3, and 2 are on and PM does not energize, check

for 115VAC at CB K1 #5 (DBU) to neutral (W). If 115VAC is not present, replace CB.

If115VAC is present, check that X10 relay is de-energized. If not, check X11 relay

status. If X11 relay is energized, replace CB. If X11 relay is de-energized and X10 relay

is energized, replace X11 relay (contacts sticking). If X10 relay is de-energized, check

for 115VAC at terminal #6 (DBU) to neutral (W) and terminal #2 (DBU) to neutral (W).

If 115VAC is present on terminal #6 (DBU) and not on terminal #2 (DBU), replace

X10relay. If 115VAC is present on X10 terminal #2 (DBU) and PM is not energized

check for 115VAC at X12 terminal #6 (DBU) to neutral (W) and X12 terminal #4 (DBU)

to neutral (W). If 115VAC is present on X12 terminal #6 (DBU) and not on X12 terminal

#4 (DBU), check for 115VAC at X12 terminal #7 (P) to X12 terminal #8 (W).

If 115VAC is not present, check CB K1 pin #2 (P) wiring for loose connection. If 115VAC

is present and X12 is not energized, check coil continuity. Replace as needed. If X12

is energized and X12 terminal #4 (DBU) does not have 115VAC, replace X12 relay

(contacts sticking). If X12 terminal #4 (DBU) has 115VAC, PM should be energized and

rotating in pump-out rotation. If not, check PM motor windings and impeller for binding.

If energized and rotating correctly, make sure the drain line is not clogged and that CV

is clean and operating properly.

Conrm LLV de-energizes. If LLV is energized with LEDs 1, 3, and 2 on, replace CB.

8) Normal Harvest Cycle – Same as the initial harvest cycle. Return to step 5a) above.

Note: Appliance continues to cycle until BC is satised or power is switched off.

The appliance always restarts at the 1-min. ll cycle.

2. Shutdown

1) See "II.D.Bin Control Check."

Legend: BC–bin control; CB–control board; Comp–compressor; CV–check valve;

FM–fan motor; FS–oat switch; HGV–hot gas valve; HPS–high-pressure switch;

LLV –liquid line valve; PM–pump motor; TXV–thermostatic expansion valve;

WV–inlet water valve

C. Control Board Check

Before replacing CB that does not show a visible defect and that you suspect is bad,

always conduct the following check procedure. This procedure will help you verify your

diagnosis.

Alarm Reset: If CB is in alarm (beeping), press the "ALARM RESET" button on CB

while CB is beeping. WARNING!Risk of electric shock. Care should be

taken not to touch live terminals. Once reset, the icemaker starts at the

1-minute ll cycle. For audible alarm information, see "III.B. LED Lights and

Audible Alarm Safeties."

1) Check the dip switch settings to assure that S4 dip switch 3, 4, 7, 8, 9, 10 and S5 dip

switch 1 through 5 are in the factory default position. S4 dip switch 1, 2, 5,6 are

cleaning adjustments and the settings are exible. For factory default settings, see

"III.C.1. Default Dip Switch Settings."

2) Move the control switch to the "ICE" position. If the red "POWER OK" LED is on, control

voltage is good, continue to step 3. If the "POWER OK" LED is off, check CT secondary

circuit. CT output is 10.5VAC at 115VAC primary input. If the secondary circuit has

proper voltage and the red LED is off, replace CB.

If the secondary circuit does not have proper voltage, check CT primary circuit. Check

for 115VAC at CB K1 connector pin #10 (LBU) to neutral (W) for 115VAC. Always choose

a white (W) neutral wire to establish a good neutral connection when checking voltages.

For additional checks, see "II.H.1. No Ice Production."

3) The "OUTPUT TEST" button provides a relay sequence test. Make sure the control

switch is in the "ICE" position, then press the "OUTPUT TEST" button. For the correct

lighting sequence, see the table below. Note that the order of the LEDs from the outer

edge of the control board is 1, 4, 3, 2. Components (e.g., compressor) cycle during the

test.

Control

Board

Correct LED

Lighting Sequence

"J" 1, 4, 3, 2

Following the test, the icemaker begins operation at the 1-minute ll cycle. If the LEDs

do not light as described above, replace CB.

4) To verify voltage output from CB to the components, slide the CB K1 connector out far

enough to allow multimeter lead contact. With the icemaker in the cycle to be tested,

check output voltage from the corresponding pin on CB K1 connector to a neutral

(Wwire). If output voltage is not found and the appropriate LED is on, replace CB.

Legend: CB–control board; CT–control transformer

D. Bin Control Check

BC shuts down the icemaker within 10 sec. when ice contacts the thermostatic bulb,

regardless of the cycle at activation.

NOTICE

When the ambient temperature is below 45°F (7°C), BC opens and shuts down

the appliance even if the ice storage bin is empty. When BC is set in the prohibited

range, the appliance operates continuously even if the ice storage bin is lled with

ice. Setting in the prohibited range may result in severe damage to the appliance.

BC is factory set, and generally no adjustment is required. However, adjustment may be

needed in some conditions, particularly at higher altitude locations.

Note: A jumper (4A4883G01) must be placed on CB red K4connector. Otherwise,

CByellow "BC OPEN" LED is on and appliance will not start.

To check BC, follow the steps below.

1) Turn off the power supply.

2) Remove the front panel, then move the control switch to the "OFF" position.

3) Remove the control box cover and base cover, then clear any ice away from BC bulb.

4) Disconnect BC wires from BC switch.

5) Hold your hand around the bulb to warm it up.

6) Check for continuity across BC switch. If closed, continue to step 6. If open, adjust or

replace BC.

7) With the multimeter test leads still in place, hold ice on BC bulb to lower the

temperature. Within 10 sec., BC switch should open. If it remains closed, adjust or

replace BC.

Legend: BC–thermostatic bin control

E. Float Switch Check and Cleaning

FS is used to determine that there is sufficient water in the water tank after the 1-min.

ll cycle and after each harvest cycle. FS is also used to determine that the appropriate

volume of water has been converted into ice before switching out of the freeze cycle. No

adjustment is required.

1. Float Switch Check

To check FS, follow the steps below.

1) Turn off the power supply.

2) Remove the front panel, then move the

control switch to the "OFF" position.

3) Drain the water tank. Remove the front

insulation panel, then slide the cube guide

to the right. Remove the rubber cap and

sleeve covering the overow pipe. See

Fig. 1. Unscrew the overow pipe. After

the water tank has drained, reconnect the

overow pipe. Replace the rubber cap,

sleeve, cube guide, and front insulation

panel in their correct positions. NOTICE!

Make sure the O-ring is attached to

the bottom of the overow pipe and be

careful not to cross thread the overow

pipe.

4) Remove the control box cover.

5) Disconnect FS connector from CB K5connector.

6) Check for continuity across FS leads. With the water tank empty, FS should be open.

If open, continue to step 7. If closed, follow the steps in "II.E.2. Float Switch Cleaning."

After cleaning FS, check it again. Replace if necessary.

7) Reconnect FS connector to CB K5 connector, then replace the control box cover in its

correct position.

8) Move the control switch to the "ICE" position. Replace the front panel in its correct

position, then turn on the power supply. After 1 min., the 1-min. ll cycle should end and

the initial harvest cycle should begin. If the initial harvest cycle begins, FS is good and

the check is complete. If the initial harvest cycle does not begin, continue to step 9.

9) Turn off the power supply.

10) Remove the front panel. Move the control switch to the "OFF" position.

11) Remove the control box cover.

12) Disconnect FS connector from CB K5 connector.

Fig. 1

Rubber Cap

Overow Pipe

Sleeve

O-Ring

Cube Guide

13) Check for continuity across FS leads. With the water tank full, FS should be closed.

IfFS is closed and the icemaker will not switch from the 1-min. ll cycle to the initial

harvest cycle, replace CB. If FS is open, conrm that the water tank is full. If the water

tank is not full, check the water supply, water lters, and inlet water valve. If the water

tank is full, follow the steps in "II.E.2. Float Switch Cleaning." After cleaning FS, check it

again. Replace if necessary.

Legend: CB–control board; FS–oat switch

2. Float Switch Cleaning

Depending on local water conditions, scale may build up on FS. Scale on the switch can

cause the oat to stick. In this case, FS should be cleaned.

1) Turn off the power supply.

2) Remove the front panel, then move the control switch to the "OFF" position.

3) Drain the water tank. Remove the rubber cap covering the overow pipe in the water

tank. Remove the overow pipe by turning it counterclockwise. After the water tank has

drained, replace the overow pipe and the rubber cap in their correct positions.

Note: Be sure the overow pipe o-ring is in its correct position on the overow pipe.

4) Disconnect the vent tube and the ush tube from the top of FS, then remove FS

assembly and remove the rubber boot from the bottom of FS assembly. See Fig. 2.

5) Remove the retainer rod from the bottom of FS housing, then remove the oat. Be

careful not to bend the retainer rod excessively when removing it.

6) Wipe down FS housing, shaft, oat, and retainer rod with a mixture of 1 part Hoshizaki

"Scale Away" and 25 parts warm water. Clean the inside of the rubber boot and hose

with cleaning solution. Rinse the parts thoroughly with clean water.

7) Reassemble FS assembly and replace it and the rubber boot in their correct positions.

Reconnect the vent tube and the ush tube.

8) Move the control switch to the "ICE" position.

9) Replace the front panel in their correct

positions.

10) Turn on the power supply to start the

automatic icemaking process.

Legend: CB–control board; FS–oat switch

Float

Float Switch

Housing

Rubber Boot

and Hose

Retainer Rod

Flush

Vent

Shaft

Fig. 2

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Hoshizaki KM-1100MAJ50 User manual

Hoshizaki KM-1100MAJ50 User manual

Hoshizaki KM-1100MAJ50 User manual

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